Synthetic roofing shingle or tile

ABSTRACT

A synthetic roofing shingle or tile is provided, in which a core material is formed, of generally less expensive material, and with a skin material provided, disposed on a plurality of surfaces of the shingle or tile, with the skin material being generally of greater expense and having desirable weather-withstanding qualities.

BACKGROUND OF THE INVENTION

[0001] In the art of making roofing shingles and tiles for exteriorapplication in the building industry, such products are made bycompression molding of multi-component formulations, which compriseblends of virgin and recycled polymers and various low cost filters.

[0002] In order to achieve low production costs, it is commonplace formanufacturers to use inexpensive raw materials, such as recycled resinof low quality with a very large amount of inexpensive filler derivedfrom various waste streams. Such filler can include carbon black,recycled rubber tire crumb, coal fines, pulp and paper waster, and otherinexpensive materials.

[0003] The use of large quantities of such fillers reduces themechanical properties of the ultimate product, however. Additionally,the use of such large quantities of fillers limits the color variationsthat are possible in the products and makes the processing of theformulations into shingles and other exterior application buildingproducts very difficult.

[0004] Typically, roofing shingles and tiles made of such materialhaving waste for filler do not provide good weather resistance for theproducts. Additionally, the warranty periods that can reasonable beprovided for such products tend to be short in duration.

[0005] Furthermore, such building industry roofing products haverelatively low impact strength, especially at low temperatures. Insofaras their available colors are concerned, such tend to be limited to thecolors gray and black.

SUMMARY OF THE INVENTION

[0006] The present invention is aimed at providing for syntheticfabrication of roofing shingles or tiles for exterior application whichare free of the above-mentioned deficiencies of the prior art.

[0007] The present invention involves a roofing shingle or tile forexterior application in the building industry, of synthetic material,comprising a core of inexpensive material weather-exposed portions ofwhich are encapsulated by a skin of a different material, preferably ofa polymer having high weather resistance and the ability to be coloredin various colors. The core material will generally be of greaterthickness than that of the skin material.

[0008] The skin material is melted and molded in some manner, and coolsand solidifies, and the less expensive but greater volume of molten corematerial is also molded, but is disposed inside the skin and both areallowed to cool and solidify, such that a core of less expensivematerial has weather-exposed portions or surfaces encapsulated by a skinof greater quality, having high weather resistance, color acceptance,and other beneficial features, such as good impact resistance, longerlifetime warranty capability and, optionally, various surface designconfigurations.

[0009] The skin and core materials can be co-injected into the same moldcavity. Alternatively, the skin material and core material can beco-extruded from melted ingredients contained within different cavitiesof a mold, so that the skin material encapsulates surfaces of the corematerial such that the skin material and core material are laminatedtogether. Also, alternatively, the core material and skin material caneach be compression molded and laminated together. Other alternativeprocesses include co-extrusion followed by stamping or embossing, blowmolding of the skin and core materials, or rotational or sequentialmolding.

[0010] Regardless of the method of making the composite skin-and-coreroofing product, three dimensional relief can be built into the moldcavity configuration or applied in a post-molding stamping or embossingoperation to be present in the skin, in order to simulate variousnatural materials such as wood shakes, tile, slate, etc.

[0011] Accordingly, it is an object of this invention to provide amulti-layer molded synthetic roofing shingle or tile, wherein a highquality thermoplastic skin layer of material encapsulates a plurality ofsurfaces of a lesser quality thermoplastic core layer of material,wherein each layer includes filler material to reduce material cost.

[0012] It is a further object of this invention to accomplish the aboveobject, wherein the core material for the product is essentially a wasteor recycled material.

[0013] It is a further object of this invention to accomplish the aboveobjects, wherein the core material comprises the greater amount ofmaterial used in making the roofing shingle or tile.

[0014] Other objects and advantages of the present invention will beapparent from a reading from the following brief descriptions of thedrawing figures, the detailed descriptions of the preferred embodiments,and the appended claims.

BRIEF DESCRIPTIONS OF THE DRAWING FIGURES

[0015] In the drawings:

[0016]FIG. 1 is a top perspective view of synthetic roofing shingle ortile in accordance with this invention.

[0017]FIG. 2 is a transverse sectional view taken through theillustration of FIG. 1, generally along line II-II of FIG. 1, whereinthe skin material is shown encapsulating the top surface and side edgesurface of the core of the article illustrated in FIG. 1.

[0018]FIG. 3 is a fragmentary longitudinal sectional view taken throughthe illustration of FIG. 1, generally along the line III-III of FIG. 1,wherein the skin material is shown encapsulating the top surface andlower edge surface of the core of the article illustrated in FIG. 1.

[0019]FIG. 4 is a perspective view of a roof, partially covered by aplurality of shingles made in accordance with the shingles of FIGS. 1-3.

DETAILED DESCRIPTIONS OF THE PREFERRED EMBODIMENTS

[0020] Referring now to the drawings in detail, reference is first madeto FIG. 1, wherein a roofing shingle or tile 10 is illustrated, in theform of synthetic roofing shingle or tile. Such article 10 is typicallyillustrated as having upper and lower surfaces 11 and 12, right and leftedge surfaces 13 and 14, and top and bottom edge surfaces 15 and 16. Thearticle 10 may take on various other configurations as may be desired,other than the flat configuration shown. Typically, if it is to be madein the form of a tile, it may be flat or it may have a rounded or archedconfiguration. One or more ends such as that 16 may be of various otherconfigurations, such as segmented, scalloped or the like, all as may bedesired. One or more surfaces 11 may have lines, grooves or seeminglyrandom relief areas 19, all as may be desired, for example to give theappearance of natural material, such as a cedar shingle, tile, slate,etc.

[0021] In general, the configurations of the various surfaces of theroofing shingle or tile 10 are unlimited as are the sizes of the same.

[0022] With reference to FIG. 2, it will be seen that the article 10 iscomprised of a skin 18 and a core 20, with the skin 18 encapsulating thetop surface 21 of the core and forming encapsulating surfaces 13, 14 and16 of the edges that would be weather-exposed.

[0023] In FIG. 4, a plurality of shingles 10 are shown applied to a roof30 of a structure 31 with lower surfaces 12 being disposed against theroof surface 30 and therefore being not weather-exposed and thereforenot needing a protective skin material 18 encapsulating surfaces 12. Topedges 15 are likewise not weather-exposed because of next-overlyingshingles covering such edges 15, so skin-encapsulation is not necessary.Right, left and especially bottom edge surfaces 13, 14 and 16,respectively, are weather-exposed and are therefore skin-encapsulated.

[0024] The core material 20 will generally be of greater thickness “T1”than the skin material 18 and will preferably be comprised of a highlyfilled polymer. The skin material 18 will preferably be comprised of apolymer having high weather resistance and the ability to be colored invarious colors as may be demanded by building designers.

[0025] By combining a skin material 18 with a core material 20, suchallows an economic advantage in that a greater amount of filler may beused to comprise the core 20, which will be of less expense than thematerial that comprises the skin, without providing undesirable surfaceproperties for the skin, and without limiting the aesthetics of theproduct, because the core 20 is encapsulated in an aestheticallypleasing and weatherable skin 18. Additionally, the core 20 can becomprised of a foam material where reduced weight for the product isdesired.

[0026] In some embodiments the shingle or tile is comprised of a core 20that is made of a low molecular weight material such as polypropylenefilled with 40-80% by weight of recycled ash with suitable functionaladditives, encapsulated in a skin 18 comprised of a film.

[0027] Such fillers as core material can vary considerably and can bechosen from a group that includes treated and untreated ashes fromincinerators of power stations, mineral fillers and their waste, pulpand paper waste materials, oil shale, reclaimed acrylic automotive paintand its waste and/or mixtures of any of these.

[0028] The skin can be chemically cross-linked to increase itsmechanical properties and weather resistance and/or flame resistance andcan contain functional additives such as pigments, UV light stabilizersand absorbers, sensibilizers (photo-initiators), etc. The cross linkingmay occur during or after processing of the material.

[0029] By way of example, the skin material 18 is selected from a groupof thermoplastic materials comprising Polyolefins such as Polyethylene(PE), Polypropylene (PP), Polymethylpentene (PMP) and Polybutene (PB-1),their copolymers, blends, and filled formulations, other polymers havinghigh weather resistance such as Polyacrylates and/or their copolymersblends and filled formulations. The skin material is preferablystabilized for UV-light and weathering resistance by using additives andadditive packages known in the state-of-the-art to be efficient. Inaddition, the skin materials may also contain various additives such asthermal and UV-light stabilizers, pigments, compatibilizers, processingaids, flame retardant additives, and other functional chemicals capableof improving processing of the materials and performance of the product.Foaming agents such as azodicarbonamide may be used to reduce thedensity of the skin material.

[0030] By way of example, the core material 20 may be selected from thegroup comprising of virgin thermoplastic polymer materials andelastomers and rubber including but not limited to Polyvinylchloride(PVC), Polyethylene (PE), Polypropylene (PP), Polybutene (PB-1),Polymethylpentene (PMP), Polyacrylates (PAC), Polyethyleneterephthalate(PET), Polybutyleneterephthalate (PBT), Polyethylenenaphthalate (PEN),Ethylene-Propylene-Diene Monomer Copolymers (EPDM), their copolymers,binary and ternary blends of the above, and filled formulations based onthe above and other thermoplastic materials and elastomers with mineral,organic fillers, nanofillers, reinforcing fillers and fibers as well asrecycled materials of the above polymers.

[0031] From the costs point of view, recycled and highly filledthermoplastic materials and recycled rubber (for example from tires) arepreferable. The content of mineral fillers can be in the weight rangefrom 5% to 80%.

[0032] In addition, the core materials may also contain variousadditives such as thermal and ultraviolet (UV) light stabilizers,pigments, compatibilizers, processing aids, flame retardant additives,and other functional chemicals capable of improving processing of thematerials and performance of the product. Foaming agents such asazodicarbonamide may be used to reduce the density of the core material.

[0033] As indicated above, the skin 18 may, if desired, be embossed orstamped after the material is processed and the item is shaped, or thesame may be molded to have relief portions to simulate embossing orstamping during the molding process.

[0034] In making the products of this invention, the combined upper andlower layers 11 and 12, of the skin 18 may comprise from 1% to 40% ofthe total thickness of the product, with the core 20 inside the skin 18being thicker between surfaces 11 and 12 and comprising the remainingpercentage of the total thickness “T” of the product.

[0035] It will be apparent from the foregoing that various othermodifications may be made in the details of making the roofing shingleor tile of this invention, all within the spirit and scope of theinvention as defined in the appended claims.

What is claimed is:
 1. A roofing element of the shingle or tile type,for exterior application, comprising a multi-layer structure having: (a)a skin including a first thermoplastic material; (b) a core including asecond thermoplastic material; (c) wherein the first material is ahighly weather resistant polymer relative to the second material; (d)wherein the second material is a polymer having filler therein and; (e)wherein the core is comprised of a substantially greater volume ofsecond material than the volume of first material that comprises theskin; and (f) wherein the skin encapsulates a plurality of surfaces ofthe core.
 2. The roofing element of claim 1, wherein the skinencapsulates surfaces of the roofing element that would beweather-exposed in the installed condition of the roofing element on aroof.
 3. The roofing element of any one of claims 1-2, wherein thepolymer of the first material is selected from the group consisting of:(a) Polyethylene; (b) Polypropylene; (c) Polymethylpentene; (d)Polybutene; (e) Polyacrylates; and (f) copolymers and/or blends of anyof (a) through (e).
 4. The roofing element of any one of claims 1-2,wherein the polymer of the second material is selected from the groupconsisting of: (a) Polyvinylchloride; (b) Polyethylene; (c)Polypropylene; (d) Polybutene; (e) Polymethylpentene; (f) Polyacrylates;(g) Polyethyleneterephthalate; (h) Polybutyleneterephthalate; (i)Polyethylenenaphthalate; (j) Ethylene-Propylene-Diene MonomerCopolymers; and (k) copolymers and/or binary or ternary blends of any of(a) through (j) above.
 5. The roofing element of claim 3, wherein thepolymer of the second material is selected from the group consisting of:(a) Polyvinylchloride; (b) Polyethylene; (c) Polypropylene; (d)Polybutene; (e) Polymethylpentene; (f) Polyacrylates; (g)Polyethyleneterephthalate; (h) Polybutyleneterephthalate; (i)Polyethylenenaphthalate; (j) Ethylene-Propylene-Diene MonomerCopolymers; and (k) copolymers and/or binary or ternary blends of any of(a) through (j) above.
 6. The roofing element of any one of claims 1-2,wherein the filler of the second material is selected from the groupconsisting of: (a) mineral filler; (b) organic filler; (c) nanofiller;(d) reinforcing filler; (e) reinforcing fiber; (f) recycled polymer ofany of; (i) Polyvinylchloride; (ii) Polyethylene; (iii) Polypropylene;(iv) Polybutene; (v) Polymethylpentene; (vi) Polyacrylates; (vii)Polyethyleneterephthalate; (viii) Polybutyleneterephthalate; (ix)Polyethylenenaphthalate; (x) Ethylene-Propylene-Diene MonomerCopolymers; and (xi) copolymers and/or binary or ternary blends or anycombinations of any of (i) through (x) above.
 7. The roofing element ofclaim 4, wherein the filler of the second material is selected from thegroup consisting of: (a) mineral filler; (b) organic filler; (c)nanofiller; (d) reinforcing filler; (e) reinforcing fiber; (f) recycledpolymer of any of; (i) Polyvinylchloride; (ii) Polyethylene; (iii)Polypropylene; (iv) Polybutene; (v) Polymethylpentene; (vi)Polyacrylates; (vii) Polyethyleneterephthalate; (viii)Polybutyleneterephthalate; (ix) Polyethylenenaphthalate; (x)Ethylene-Propylene-Diene Monomer Copolymers; and (xi) copolymers and/orbinary or ternary blends or any combinations of any of (i) through (x)above.
 8. The roofing element of any one of claims 1-2, wherein thefirst material includes at least one additive therein, with saidadditive(s) being selected from the group consisting of: (a) thermalstabilizers; (b) ultraviolet light stabilizers; (c) pigments; (d)compatibilizer(s); (e) flame retardants; and (f) processing aids.
 9. Theroofing element of any one of claims 1-2, wherein the second materialincludes at least one additive therein, with said additive(s) beingselected from the group consisting of: (a) thermal stabilizers; (b)ultraviolet light stabilizers; (c) pigments; (d) compatibilizer(s); (e)flame retardants; and (f) processing aids.
 10. The roofing element ofany one of claims 1-2, wherein each of said first and second materialsinclude at least one additive therein, with said additive(s) beingselected from the group consisting of: (a) thermal stabilizers; (b)ultraviolet light stabilizers; (c) pigments; (d) compatibilizer(s); (e)flame retardants; and (f) processing aids.
 11. The roofing element ofclaim 3, wherein the first material includes at least one additivetherein, with said additive(s) being selected from the group consistingof: (a) thermal stabilizers; (b) ultraviolet light stabilizers; (c)pigments; (d) compatibilizer(s); (e) flame retardants; and (f)processing aids.
 12. The roofing element of claim 4, wherein the secondmaterial includes at least one additive therein, with said additive(s)being selected from the group consisting of: (a) thermal stabilizers;(b) ultraviolet light stabilizers; (c) pigments; (d) compatibilizer(s);(e) flame retardants; and (f) processing aids.
 13. The roofing elementof claim 5, wherein the first and second materials each include at leastone additive therein, with said additive(s) being selected from thegroup consisting of: (a) thermal stabilizers; (b) ultraviolet lightstabilizers; (c) pigments; (d) compatibilizer(s); (e) flame retardants;and (f) processing aids.
 14. The roofing element of claim 8, wherein thefiller of the second material is selected from the group consisting of:(a) mineral filler; (b) organic filler; (c) nanofiller; (d) reinforcingfiller; (e) reinforcing fiber; (f) recycled polymer of any of; (i)Polyvinylchloride; (ii) Polyethylene; (iii) Polypropylene; (iv)Polybutene; (v) Polymethylpentene; (vi) Polyacrylates; (vii)Polyethyleneterephthalate; (viii) Polybutyleneterephthalate; (ix)Polyethylenenaphthalate; (x) Ethylene-Propylene-Diene MonomerCopolymers; and (xi) copolymers and/or binary or ternary blends or anycombinations of any of (i) through (x) above.